PowerFlex 700 Drive - Frame 8 Components … Automation Publication 20B-IN024C-EN-P - June 2012 9...

PowerFlex 700 Drive - Frame 8 Components Replacement

Installation Instructions

Important User Information

Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

Allen-Bradley, Rockwell Software, Rockwell Automation, PowerFlex, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

http://literature.rockwellautomation.com/idc/groups/literature/documents/in/sgi-in001_-en-p.pdfhttp://www.rockwellautomation.com/literature/

Table of Contents

Summary of Changes New and Updated Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Preface Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Component Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Important Initial Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Chapter 1Component Diagrams and Torque Specifications

Drive Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Fastener Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Chapter 2Basic Component Removal Procedures

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Main Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Stacking Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Transitional Busbar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Chapter 3Component Replacement Procedures Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Main Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

T-Comm Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Power Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Switch Mode Power Supply Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Precharge Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Rockwell Automation Publication 20B-IN024C-EN-P - June 2012 3

Table of Contents

DC Bus Filter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Bus Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Capacitor Bank Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Balancing Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Inverter Power Module (IGBT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Gate Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Current Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Converter Power Module - (SCR) AC Input Only . . . . . . . . . . . . . . . . . . 56Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Converter Snubber Resistors - AC Input Only . . . . . . . . . . . . . . . . . . . . . . 58Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Converter Snubber Board - AC Input Only. . . . . . . . . . . . . . . . . . . . . . . . . 59Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Fan Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Heatsink Fan - Removal from Back of Drive . . . . . . . . . . . . . . . . . . . . . . . . 61Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Heatsink Fan - Removal from Front of Drive . . . . . . . . . . . . . . . . . . . . . . . 63Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Thermal Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

DC Link Choke - AC Input Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Remove Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Install Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

4 Rockwell Automation Publication 20B-IN024C-EN-P - June 2012

Table of Contents

MOV Surge Suppressor - AC Input Only . . . . . . . . . . . . . . . . . . . . . . . . . . 71Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Precharge SCR Module and Diode - DC Input Only . . . . . . . . . . . . . . . . 72Remove Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Install Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72


Table of Contents

Notes:


Summary of Changes

New and Updated Information

This table contains the changes made to this revision.

Topic Page

Added additional resources table. 11

Updated the torque specifications table. 21

Updated torques and steps for these install components procedures:

Main control panel 25

Stacking panel 27

Transitional busbar assembly 32

Main control board 36

T-comm board 39

Power interface board 41

Switch mode power supply board 42

Precharge board 43

Bus capacitor 46

Capacitor bank fan 47

Balancing resistor 48

Balancing resistor 51

Gate interface board 53

Current transducer 55

Converter power module (SCR) AC input only 57

Converter snubber resistors AC input only 59

Converter snubber board AC input only 60

Fan transformer 60

Heatsink fan - removal from back of drive 62

Heatsink fan - removal from front of drive 67

Thermal sensor 69

DC link choke AC input only 70

MOV surge suppressor AC input only 71

Precharge SCR module and diode DC input only 72


Summary of Changes

Notes:


Preface

Introduction This publication provides guidelines for replacing the major components in the PowerFlex 700 Frame 8 drive.

Component Kits All kits include necessary components, ESD wrist strap and hardware (if required), and thermal grease (if required).

Description Kit Catalog No. NotesPrinted Circuit BoardsGate Interface Board SK-G1-GDB1-F8910 Drive requires three kitsPrecharge Board SK-G9-PRE1-V480 AC input

1336-PB-SP22C DC inputPower Interface Board SK-G9-GDB1-D365 365A drives

SK-G9-GDB1-D415 415A drivesSK-G9-GDB1-D481 481A drivesSK-G9-GDB1-D535 535A drivesSK-G9-GDB1-D600 600A drives

Main Control Board SK-G9-VMCB1-D0 115V I/OSK-G9-VMCB1-C0 24V I/O

T-Comm Board SK-G9-TCOMMSwitch Mode Power Supply Board SK-G9-PWRS1-D0DC Bus Filter Board 2364-SPP02AFans and Main Fan Circuit ComponentsHeatsink Fan SK-G1-FAN1-F810 Includes fan and fan enclosure.Capacitor Fan SK-G1-FAN2-F8910Power Module Sub-assembliesInverter Power Module (IGBT) SK-G1-QOUT1-F8 Includes:

One IGBT module One gate interface board Gate interconnect harness Six flexible capacitor busbars Three snubber capacitors One tie down capacitor mountDrive requires three kits.

Converter Power Module (SCR) SK-G1-SCR1-F89 AC input. Kit includes three SCR modules.

SCR Snubber Kit SK-G1-SCRSNUBRB AC input drive requires three kits.DC Precharge SCR Module SK-G1-SCR2-F89 DC input.

Includes: One SCR module One diode

MiscellaneousCurrent Transducer SK-G1-CT1-F8 Includes one transducer.

Drive requires three kits.Thermal Sensor Kit SK-G1-THM1-F89 AC input.

Includes: Main control panel thermal sensor Heatsink thermal sensor

SK-G1-THM2-F89 DC input.Includes: Main control panel thermal sensor Heatsink thermal sensor


Preface

Refer to the master parts list for the most recent information:

http://www.ab.com/support/abdrives/powerflex70/PF7ReleasedParts.pdf

Miscellaneous (continued)Bus Capacitor Kit SK-G1-BUSCAP1-F8 365A, 415A and 481A only.

Includes one capacitor.Drive requires 18 kits.

SK-G1-BUSCAP2-F8 535A and 600A only.Includes one capacitor.Drive requires 18 kits.

Capacitor Bus Finger Kit SK-G1-FLXBUS1 Included with the kit for inverter power module (IGBT).Can be ordered separately.Includes: Three positive flexible capacitor

busbars Three negative flexible capacitor

busbarsMOV Surge Suppressor SK-G1-MOV1-F89 AC input.Power Supply, 24V SK-G9-PWRS24DC Link Choke SK-G1-DCCHOKE1-F8 AC input.Transformer, 500 VA SK-G9-XFMR1-F89 AC input.

Includes One transformer Three fuses

Transformer Fuses SK-G9-FUSE1-F8 AC input.Includes three fuses.

Balancing Resistor 1336-RLOAD-SP3A Includes one resistor.

IMPORTANT Refer to the instruction sheet included with each component kit for instructions regarding discarding or returning replaced components.

If discarding, be sure to discard according to local, state, and federal regulations.

Description Kit Catalog No. Notes


http://www.ab.com/support/abdrives/powerflex70/PF7ReleasedParts.pdf

Preface

Recommended Tools The following list includes the most common tools used to disassemble and assemble the drive and components. This list may not include all the tools for your situation. Not all tools are needed for some components. Refer to the specific sections for details.

Additional Resources These documents contain additional information concerning related products from Rockwell Automation.

You can view or download publications at http:/www.rockwellautomation.com/literature/. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative.

Description

Torque wrench (metered in Nm or lbin)

Volt ohm meter

Torque seal or colored marker

Screwdrivers (standard, Phillips, torx various sizes)Magnetic screwdriver, long

Socket set, metric

Cylindrical pick-up magnet

Pliers, regular and needle-nose

Wire cutters

Isopropyl alcohol and applicator cloth

Nylon tie wraps

3- or 4-inch paint roller with short nap or 3- or 4-inch putty knife (for installing SCR modules)

Pencil

Resource Description

PowerFlex 700 Adjustable Frequency AC Drive Frames 7 . . . 10 Installation Instructions, publication 20B-IN014

Provides basic information needed to mount, wire, and start-up a PowerFlex 700 drive.

PowerFlex 700 AC Drives User Manual, publication 20B-UM002

Provides basic information needed to install, start-up and troubleshoot the PowerFlex 700 drive.

Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1

Provides general guidelines for installing a Rockwell Automation industrial system.

Product Certifications website, http://www.ab.com Provides declarations of conformity, certificates, and other certification details.


http://literature.rockwellautomation.com/idc/groups/literature/documents/in/20b-in014_-en-p.pdfhttp://literature.rockwellautomation.com/idc/groups/literature/documents/um/20b-um002_-en-p.pdfhttp://literature.rockwellautomation.com/idc/groups/literature/documents/in/1770-in041_-en-p.pdfhttp://www.ab.comhttp://www.rockwellautomation.com/literature/

Preface

Safety Precautions The precautions and general installation requirements provided in the PowerFlex 700 Frame 7 . . . 10 Installation Instructions (publication 20B-IN014) and the PowerFlex 700 User Manual (publication 20B-UM002) must be followed in addition to those included here.

1. Turn off and lock out input power. Wait five minutes.

2. Verify that there is no voltage at the drives input power terminals.

3. Check the DC bus voltage at the power terminals by measuring between the +DC and DC terminals, between the +DC terminal and the chassis, and between the DC terminal and the chassis. The voltage must be zero for all three measurements.

ATTENTION: To avoid an electric shock hazard, ensure that all power has been removed before proceeding. In addition, before servicing, verify that the voltage on the bus capacitors has discharged. Check the DC bus voltage at the Power Terminals by measuring between the +DC & DC- terminals, between the +DC terminal and the chassis, and between the DC- terminal and the chassis. The voltage must be zero for all three measurements.

Remove power before making or breaking cable connections. When you remove or insert a cable connector with power applied, an electrical arc may occur. An electrical arc can cause personal injury or property damage by:

sending an erroneous signal to your systems field devices, causing unintended machine motion.

causing an explosion in a hazardous environment.Electrical arcing causes excessive wear to contacts on both the module and its mating connector. Worn contacts may create electrical resistance.


http://literature.rockwellautomation.com/idc/groups/literature/documents/in/20b-in014_-en-p.pdfhttp://literature.rockwellautomation.com/idc/groups/literature/documents/um/20b-um002_-en-p.pdf

Preface

Important Initial Steps Read and follow these statements before performing any service on the drive. Read and follow the precautions in Safety Precautions on page 12. Identify components to be replaced using the figures in Chapter 1. Remove protective shields only as necessary. Before disconnecting any wire or cable, verify that it is labeled. Also, when

removing components, note hardware type and location. When torquing any fasteners, use a colored marker or torque seal to mark

each screw after torquing so you know when all are done and to indicate signs of any subsequent tampering.

Refer to the product installation documentation for startup and other instructions after servicing.

ATTENTION: This assembly contains parts and sub-assemblies that are sensitive to electrostatic discharge. Static control precautions are required when servicing this assembly. Component damage may result if you ignore electrostatic discharge control procedures. If you are not familiar with static control procedures, refer to Guarding Against Electrostatic Damage, Allen-Bradley publication 8000-4.5.2, or any other applicable ESD protection handbook.

The information in this publication is merely a guide for proper installation. Rockwell Automation, Inc. cannot assume responsibility for the compliance or the noncompliance to any code (national, local, or otherwise) for the proper installation of this drive or associated equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored.

Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation, start-up, and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage.

Hot surfaces can cause severe burns. Do not touch the heatsink surface during operation of the drive. After disconnecting power, allow time for cooling.

Replace all protective shields before applying power to the drive. Failure to replace protective shields may result in death or serious injury.


http://literature.rockwellautomation.com/idc/groups/literature/documents/sb/8000-sb001_-en-p.pdf

Preface

Notes:


Chapter 1

Component Diagrams and Torque Specifications

Drive Components Figure 1 - Frame 8 AC Drive Components

Converter Snubber Board (3)

SCR Converter Power Module

MOV Surge Suppressor

Converter Snubber Resistors (3)

Current Transducer (3)

Gate Interface Board (3)

Output Busbar (3)

Converter Busbar (2)

DC- Busbar

AC Busbars (R, S, T)

Balancing Resistor

Snubber Capacitors for IGBTs (9)

Capacitor Bank Fan

IGBT Interface Board and IGBT (3)

Flexible Capacitor Busbars (18)

DC Bus Capacitor (18)

Motor Busbars (U, V, W)

Drive Shown With Stacking Panel Removed

Tie Down Capacitor Mount

PE Ground (and MOV Wire)

Fan Transformer Busbar Mounting Plate(Heatsink Fan is behind this plate)

Transitional Busbar

DC+ Busbar

AC Output Busbar (3)


Chapter 1 Component Diagrams and Torque Specifications

Figure 2 - Frame 8 DC Drive Components


Gate Interface Board (3)

Output Busbar (3)

Precharge Busbar (bottom)

Balancing Resistor

Snubber Capacitors for IGBTs (9)

Capacitor Bank Fan

IGBT Interface Board and IGBT (3 each)

Flexible Capacitor Busbars (18)

DC Bus Capacitor (18)

Motor Busbars (U, V, W)

Drive Shown With Stacking Panel Removed


Precharge Resistors (2)

Busbar Mounting Plate(Heatsink Fan is behind this plate)

Transitional Busbar

Precharge Fuse

Precharge Busbar (top)

DiodePrecharge SCR Module

AC Output Busbar (3)


Component Diagrams and Torque Specifications Chapter 1

Figure 3 - Frame 8 Busbars (AC Drive shown)

DC- Busbar

Transitional Busbar Assembly

DC+ Busbar



Figure 4 - Frame 8 (AC input drive shown)

Inverter Snubber Capacitors (3 per IGBT)


Gate Interface Board

Heatsink Thermal Sensor Connector (J8 on each Gate Interface Board)

Motor Busbars

Inverter Power Module IGBT (W) under Capacitors (V and U below W)

Precharge Board

Power Interface Board (under Main Control Panel)

Transitional Busbar

Main Control Panel

DC Link Choke

Main Control Panel Thermal Sensor and Wire

DC Capacitor Bank (Under Transitional Busbar)

HIM (Blank shown on this Drive)

TB11

DC Bus Filter Board

Ribbon Cable - Main Control Board to Comm Board

HIM Cradle

Ribbon Cable - Main Control Board to Power Interface Board (shown disconnected)

IGBT Gate Harness and CT Harness

Fan Transformer

Main Control Board (under HIM Cradle)

Fan Terminal Block TB9

Stacking Panel

W

V

U

DC Link Choke Output Connection (Top)

DC Link Choke Output Connection (Bottom)

DC Link Choke Input Connection (Bottom)

DC Link Choke Input Connection (Top)

Balancing Resistor



Circuit Boards Figure 5 - Circuit Boards on Frame 8

T-Comm Interface

No. Description

1 DC bus filter board

2 Precharge board

3 HIM cradle/board

4 Main control board

5 Power interface board

6 Switch mode power supply board

7 Communication board slots (optional)

8 Encoder board (optional)

Communications Panel

Main Control Panel

Stacking Panel



Fastener Torque Specifications

Torque Sequence

The following illustrates initial and final tightening sequences for components fastened to a heatsink using two, four, and six screws. Initial torque is 1/3 (33%) of final torque, except six-point mountings, which require 0.7 Nm (6 lbin.) The numeric illustration labels are for your assistance. Drive components do not carry these labels.

Figure 6 - Various-point Mounting

ATTENTION: When mounting components to a drives heatsink, component fastener torque sequences and tolerances are crucial to component-to-heatsink heat dissipation.

Components can be damaged if initial tightening procedure is not performed to specification.

Initial Torque Sequence

FinalTorque Sequence

Two-Point Mounting

Start End End Start

1 2 12


FinalTorque Sequence

Four-Point Mounting

End

Start

Start

End

1 2 4 33 4 2 1

Note: Do not exceed 0.7 Nm (6 lbin) on initial torque.


Six-Point Mounting

Start

End

Final Torque Sequence

Start

End

6 2

3 1

4

5

6 2

3 1

4

5



Torque Specifications

The following table lists fastener locations by component, how the fasteners are used, and torque specifications. Refer to Torque Sequence in this chapter for fastening two-point, four-point, and six-point components to the heatsink.

Torque

Component Fastener Application Nm lbin

20-Comm-x board fasten to HIM cradle/board 2.9 26

AC busbars (R, S, and T) fasten to converter SCR module 9 80

AC output busbar fasten to standoffs on heatsinkfasten to IGBT

5.65.6

5050

Balancing resistor fasten to the transitional busbar 2.9 26

Balancing resistor wires black: negative () busbaryellow: bus capacitor busbarblue: converter (+) busbar

2.92.92.9

262626

Busbars (DC+ and DC-) fasten upper busbar mounts to the converter busbars 23.5 208

Busbar mounting plate fasten the busbars to the bottom of the chassis 6 50

Busbar mounting plate bracket (left) fasten to the left side of the converter busbar 6 50

Bus capacitor busbar fasten to the capacitor setscrews (short) 5.6 50

Cables fasten +DC IN and +DC OUT cables to the transitional busbar 23.5 208

Capacitor bank fan fasten to chassis below the capacitor bank 1.8 16

Capacitor setscrews short setscrew fastens capacitor to the bus capacitor busbarlong setscrew fastens capacitor to the transitional busbar

0.70.7

66

Communications panel fasten to the main control paneltop of the communications panelbottom of the communications panel

5.62.9

5026

Converter busbars fasten to converter SCR modules 9 80

Converter power modules (SCR) AC input only fasten to heatsink:first sequencefinal sequence

0.75.6

650

Converter SCR modules wiring fasten to the busbar connection at the SCR module 2.9 26

Converter snubber board AC input only fasten to the standoffs on the converter busbars 2.9 26

Converter snubber resistors AC input only fasten to the frame around the heatsink 2.9 26

Current transducer brackets fasten the mounting brackets to the current transducer 1.6 14

Current transducer assembly fasten to the backplane 2.9 26

DC bus filter board fasten to glastic standoffs on stacking panel 1.7 15

DC link choke AC input only fasten mounting brackets to the bottom of the chassisfasten cables to the choke connectors

99

8080

Encoder board (optional) fasten to standoffs on main control board 2 14

Heatsink fan cover fasten to the back of the drive 2.9 26

Heatsink fan mounting plate fasten the heatsink fan to the fan mounting plate 2.9 26

Fan transformer fasten to the mounting plate below the capacitor bank fan 5.6 50



Flexible capacitor busbars fasten to the transitional busbarfasten to the IGBT module

5.65.6

5050

Gate interface board fasten to upright bracket on heatsink 1.8 16

Ground wire (green and yellow) from TB11 to the HIM cradle/board 1.6 14

HIM cradle/board fasten to the main control panel 2.9 26

IGBT module fasten to the heatsink:first sequencesecond sequencefinal sequence

0.72.35.6

6.02050

Main control board fasten to the main control panel 2 14

Main control panel fasten to the stacking panel:top of the main control panelbottom of the main control panel

5.62.9

5026

MOV surge suppressor AC input only fasten to the chassis 2.9 26

MOV surge suppressor AC input only (wiring) fasten black wires to R, S, and T busbar connection at the SCR modulesfasten green and yellow ground wire to ground stud at the bottom of the chassis

2.99.0

2680

Output busbar fasten to the AC output busbarfasten to the U, V, or W busbarsetscrew and nut to the U, V, or W busbar

9.09.05.6

808050

Power interface board fasten to stacking panel 1.7 15

Precharge board fasten to stacking panelfor AC inputfor DC input (1/4 turn clockwise)

1.7

15

Precharge SCR module and diode DC input only fasten to the heatsink:first sequencefinal sequence

0.75.6

6.050

Precharge busbars DC input only fasten to the SCR module and diode 5.6 50

Precharge wires DC input only fasten to the precharge busbars 2.9 26

Precharge power cables DC input only fasten to the precharge busbars 12.2 108

Snubber resistors fasten to the IGBT setscrews at the tie down capacitor mount 5.6 50

Stacking panel fasten to the chassis 5.6 50

Switch mode power supply board fasten to stacking panel 1.7 15

Thermal sensors fasten to heatsinkfasten to main control panel

hand tightenhand tighten

Tie down capacitor mount fasten to the bracket at left of IGBT board 5.6 26

Transitional busbar mounting brackets to the glastic spacersmounting brackets to the drivefasten to the bus capacitor setscrews

5.62.95.6

502650

Torque

Component Fastener Application Nm lbin


Chapter 2

Basic Component Removal Procedures

Overview Component removal and replacement in this chapter are located on the stacking panel and transitional busbar assemblies highlighted below.

See Circuit Boards on page 19 to identify the various panels that comprise the stacking panel assembly.


Stacking Panel Assembly

Main Control Panel Assembly


Chapter 2 Basic Component Removal Procedures

Main Control Panel See Chapter 1 - Component Diagrams and Torque Specifications to locate the component detailed in these instructions.

Remove Components

1. Read and follow the Safety Precautions on page 12 and Important Initial Steps on page 13.

2. Remove the ribbon cable going from the main control board ( J2) to the power interface board ( J1).

3. Disconnect the incoming ground wire to TB11.

4. Remove the two screws on the main control panel below TB11.

5. Remove the two mounting nuts at the top of the main control panel.

6. Disconnect the wire harnesses from TB11 to the switch mode power supply board ( J4 connector) and at TB1 and TB2 on the power interface board.

7. Label and remove all customer wiring from TB11.

8. Remove the main control panel and carefully set aside.

Ribbon Cable

Mounting Nuts (2) at top of Main Control Panel

Ground Wire to TB11MCP Mounting Screws (2) below TB11


Ground Wire to TB11MCP Mounting Screws (2) below TB11


Ground Wire to TB11Main Control Panel Mounting Screws (2) below TB11


Basic Component Removal Procedures Chapter 2

Install Components

1. Replace any customer wiring to TB11.

2. Connect the wire harnesses from TB11 to the switch mode power supply board ( J4 connector) and at TB1 and TB2 on the power interface board.

3. Torque the two mounting nuts at the top of the main control panel to 5.6 Nm (50 lbin).

4. Torque the two screws on the main control panel below TB11 to 2.9 Nm (26 lbin).

5. Connect the incoming ground wire to TB11.

6. Connect the ribbon cable going from the main control board ( J2) to the power interface board ( J1).

7. Replace all safety shields and enclosure covers before applying power to the drive.



Stacking Panel See Chapter 1 - Component Diagrams and Torque Specifications to locate the component detailed in these instructions.

Remove Components


2. Label and disconnect wiring as listed below.

3. Disconnect the main control panel thermal sensor and wire located above the main control board, from the wiring harness (see Figure 4 - on page 18).

TIP Remove the main control panel first to provide better access to wiring and fasteners. See Main Control Panel on page 24.

Connected Component

Label on Wire or Connector

Label on Board

Notes

Precharge board J2, J3 J2, J3DC bus filter board TB1 TB1Power interface board J8 J8

J16 U U phase CTJ15 V V phase CTJ14 W W phase CTJ23 UP, VP, WP U, V, W positive gatesJ18 UN, VN, WN U, V, W negative gatesJ6 J6

TB11 Customer wiring Remove if not already done

J2

J3

TB2

J8

J16J14

J18

J23

J6

Shown without main control panel.NOTE: Mounting position of boards on stacking panel may vary.

TB1

Precharge Board

Power Interface Board

DC Bus Filter Board



4. Remove the six nuts for mounting the stacking panel.

5. Remove the stacking panel; carefully set aside.

Install Components

1. Torque the six mounting nuts to 5.6 Nm (50 lbin).

2. Connect the main control panel thermal sensor and wire located above the main control board.

3. Connect all wiring that was removed.


Mounting Nuts (6)

Shown without main control panel.NOTE: Mounting position of boards on stacking panel may vary.




See Chapter 1 - Component Diagrams and Torque Specifications to locate the component detailed in these instructions.

Remove Components


2. Remove the stacking panel as detailed on page 26.

3. If present, remove all customer wiring to transitional busbar.

4. For AC input drives, remove the DC choke output cables.

For DC input drives, there is no choke.

5. If present, disconnect the +DC IN and +DC OUT cables from the transitional busbar.

DC Choke Output Cables

Transitional Busbar

Balancing Resistor



6. Remove all IGBT Snubber components:a. Remove the six nuts that secure each set of snubber capacitors. Remove

the capacitors, and save nuts and capacitors.

b. Remove the two screws that secure each tie down capacitor mount. Remove the tie down capacitor mounts and save screws and capacitor mounts.

c. Remove the six setscrews from each IGBT and save.

If replacing an IGBT module, remove the nuts and DC flexible capacitor busbars, and save nuts and busbars.

7. Cut tie wraps for the balancing resistor wiring.

Snubber Capacitors

Snubber Capacitor

Mount Nuts

Tie Down Capacitor

Mount Screw

Tie Down Capacitor

Mount Screw

Nuts for DC Flexible

Capacitor Busbars

Setscrews



8. Disconnect the yellow wire for the balancing resistor.

You do not need to disconnect the blue and black wires.

9. Remove the four side standoffs and brackets for the transitional busbar assembly.

10. Remove the 18 nuts fastening the transitional busbar assembly to the bus capacitors.

The setscrews may come out with the nuts. Save all nuts and setcrews.

Balancing Resistor

Balancing Resistor yellow wire

Disconnect here

Resistor wiring tie wraps

Transitional Busbar Nuts (18) attached to Setscrews

Side Standoffs and Brackets (4)

DC Choke Output Cables

Balancing Resistor

Transitional Busbar

Photo shows setscrews in Capacitors; these setscrews may come out with the Transitional Busbar nuts when they are removed.



11. Remove the transitional busbar assembly.

Positive (DC+) Flexible Capacitor Busbar (attached to bottom side of Transitional Busbar)

Negative (DC-) Flexible Capacitor Busbar (attached to top side of Transitional Busbar)



Install Components

See the photographs in the preceding Transitional Busbar Assembly section to identify any components discussed in this section.

1. Replace the three positive (DC+) flexible capacitor busbars supplied in an IGBT replacement kit on the back side of the transitional busbar for each IGBT module being replaced.

2. Mount transitional busbar to bus capacitors. If needed, use a rubber mallet to gently tap the transitional busbar onto the longer setscrews of the bus capacitors.

3. Add a washer (rounded side down) and nut to each bus capacitor setscrew. Finger tighten only.

4. Install the nine negative flexible capacitor busbars to the transitional busbar with two washers (rounded side down) and two nuts for each flexible capacitor busbar. Finger tighten only.

5. Install the six setscrews to secure the flexible capacitor busbars to each IGBT board. Finger tighten only.

IMPORTANT Each IGBT replacement kit includes three positive (DC+) and three negative (DC-) flexible capacitor busbars. The positive ones are shorter (see above) because they attach to the back side of the transitional busbar. For ease of installation, replace positive flexible capacitor busbars while the transitional busbar is removed.

Negative (DC-) Flexible Capacitor Busbar (tall)

Positive (DC+) Flexible Capacitor Busbar (short)



6. Reinstall the screws for the four side standoffs and brackets to secure the transitional busbar assembly to the chassis.a. Torque the screws to 5.6 Nm (50 lbin) to secure the brackets to the

four red glastic spacers.b. Torque screws to 2.9 Nm (26 lbin) to secure the two brackets to the

drive chassis.

7. Torque the six setscrews for each IGBT board to 5.6 Nm (50 lbin).

8. Reinstall the tie down capacitor mount on each IGBT board.

Reinstall two screws simultaneously to secure each Mount. Torque screws to 2.9 Nm (26 lbin).

9. Install three snubber resistors onto the six setscrews for each IGBT board.

Reinstall two screws to secure each snubber resistor against the tie down capacitor mount. Torque screws to 5.6 Nm (50 lbin).

10. Torque the nuts that secure the nine negative flexible capacitor busbars to the transitional busbar to 5.6 Nm (50 lbin).

11. Torque the nuts that secure the transitional bus bar to the bus capacitor setscrews to 5.6 Nm (50 lbin).

12. Connect the yellow wire for the balancing resistor.

13. Install a new tie wrap for the balancing resistor wiring.

14. If present, connect the +DC IN and +DC OUT cables from the transitional busbar. Torque to 23.5 Nm (208 lbin).

15. For AC input drives, reinstall the DC choke output cables. Torque to 9 Nm (80 lbin).

16. Reinstall any customer wiring to the transitional busbar.

17. Reinstall the stacking panel as instructed on page 27.

18. Verify all wiring to the two panels and the transitional busbar has been reconnected.


IMPORTANT When torquing down each setscrew, place a flathead screwdriver against the side of the flexible capacitor busbar to minimize twisting. Do not rest the screwdriver against any IGBT board while performing this task to avoid cracking or breaking the board.



Notes:


Chapter 3

Component Replacement Procedures

Overview Component procedures detailed in this chapter apply to PowerFlex 700 Frame 8 drives for AC or DC input. Removal and replacement instructions for the stacking panel and transitional busbar assemblies are detailed in Chapter 2.

Main Control Board See Chapter 1 - Component Diagrams and Torque Specifications to locate the component detailed in these instructions.

Remove Components


2. Remove safety shields as needed.

3. Unscrew the green/yellow ground wire from the communications panel.

4. Remove the two nuts and two screws and washers for the communications panel.

Screw for green/yellow Ground Wire

Release Cable from Clamp

Nuts (2)

Screws and Washers (2 each)

Communications Panel (Located over main control panel)


Chapter 3 Component Replacement Procedures

5. Disconnect both ribbon cables from the left side of the main control board.

6. Hold the communications panel and release the cable at the bottom of the panel from its clamp (see previous page for its location) and set the communications panel aside.

7. If needed, unscrew and disconnect the connector from the main control board for the wire set going to TB11.Do not disconnect any wires from TB11.

8. If present, unscrew the two screws for the encoder board. Gently pull off the encoder board.

9. Unscrew the four screws and two hex standoffs holding the main control board.

10. Remove the main control board.

Install Components

1. Install the new main control board with four screws and two hex standoffs. Torque the screws and standoffs to 2 Nm (14 lbin).

2. Install the encoder board (if the optional encoder board was installed) with two screws. Be sure to match up the J7 connectors. Torque the screws to 2 Nm (14 lbin).

3. Connect the ribbon cable and TB11 cable connector to the main control board.

4. Torque the two mounting nuts at the top of the communications panel to 5.6 Nm (50 lbin).

5. Torque the two screws on the communications panel near TB11 to 3 Nm (26 lbin).

6. Torque the screw for the green/yellow ground wire from TB11 to the HIM cradle/board to 1.6 Nm (14 lbin).


Ribbon Cable (1 of 2)

Main Control Board Screws (4)

TB11 Cable Connector

Main Control Board

Encoder Board(Optional)

Encoder Board Screws (2); Hex standoffs (2) are between both boards


Component Replacement Procedures Chapter 3

T-Comm Board See Chapter 1 - Component Diagrams and Torque Specifications to locate the component detailed in these instructions.

Remove Components


2. Remove the main control board:a. Remove the HIM board from its slot (if used).b. Disconnect the ribbon cable from the main control board (connects to

J1on power interface board).c. Disconnect the wiring connector from the main control board

(connects to 8-pin serial port in the lower-right corner of main control board panel).

d. Remove and save the grounding-wire screw (connects to PE on TB11).e. Remove and save the two mounting screws for the HIM cradle/board.f. Remove the HIM cradle/board.

HIM Board slot

Mounting Screw

Optional 20-Comm-x Board Detail

Ribbon Cable Connector

Grounding-Wire Screw

Wiring Connector

Ribbon Cable Connection to T-Comm Board

Mounting Screws (4)

Mounting Screw



3. Remove the 20-Comm-x board (if used):a. Disconnect the ribbon cable between the 20-Comm-x Board and

T-Comm board; disconnect only from the T-Comm board.b. Remove and save the four mounting screws.

4. If the 20-Comm-x board is not used, remove the screw securing the T-Comm grounding tab.

5. Place the tip of a flathead screwdriver between the T-Comm grounding tab and screw mount.

Gently pry up until the grounding tab is in an upright position or about 90 degrees from the screw mount.

6. If needed, use the same flathead screwdriver tip to pry the seven locking tabs away from the T-Comm board.

7. Remove the T-Comm board from the main control board.

T-Comm grounding tab screw T-Comm grounding tab flat T-Comm grounding tab upright

T-Comm Board Locking Tab Locations

Five locking tabs are on the back side of the main control board (above); two are on the front side in the area between the optional HIM and 20-Comm-x board slots (upper right).

NOTE: Use a flathead screwdriver tip to pry the locking tabs away from the T-Comm Board (lower right).



Install Components

1. Install the new T-Comm board.

2. Verify the board is locked into all seven locking tabs.

3. Carefully bend the T-Comm grounding tab until it is flush with the screw mount on the main control board.

4. Install the 20-Comm-x board (if used). Torque the four mounting screws to 2.9 Nm (26 lbin).

5. Install the HIM cradle/board. Torque the two mounting screws to 3 Nm (26 lbin).

6. Install the screw for the green/yellow ground wire from TB11 to the HIM cradle/board. Torque the screw to 1.6 Nm (14 lbin).

7. Connect the 8-pin wiring connector to the serial port.

8. Connect the ribbon cable.




Power Interface Board See Chapter 1 - Component Diagrams and Torque Specifications to locate the component detailed in these instructions.

Remove Components


2. Remove the main control panel as detailed on page 24.

3. Remove remaining wiring harnesses from the power interface board, including the wiring between the power interface board and the switch mode power supply board.

Refer to the illustration above for connector locations.

Connector Wire Color(s) Connects To:

J1 ribbon J2 on main control board (ribbon cable)

J2 black J1 on switch mode power supply board

J6 black Monitor wire to thermal sensors

J8 red/white/black J7-U on U phase gate interface board

J9 red/white/black J1 on 24V power supply board

J10 red/black/white/blue J3 on precharge board

J12 red/white J3 on switch mode power supply board

J13 black J2 on switch mode power supply board

J14 red/white/black U phase current transducer

J15 red/white/black V phase current transducer

J16 red/white/black W phase current transducer

J18 blue/white U, V, W negative () gates (lower phase)

J23 orange/black U, V, W positive (+) gates (upper phase)

DC input shown

J1

J10

J8

J9

J16J15J14

J24

J13

J23

J18

TB2

J6

TB1

J2

Spacers (9)

J12



4. Remove the two power interface board mounting torx screws located at the upper right and lower left corners of the board as shown at right.

5. Use your fingers or needle-nose pliers to squeeze the tabs of each of the nine spacers (see previous page for their locations), and separate the power interface board from the mounting plate.

6. Remove the power interface board.

Install Components

1. Install the new power interface board. Torque the two mounting screws to 1.7 Nm (15 lbin).

2. Connect all wiring. For the ribbon cable going from the power interface board ( J1) to the main control board ( J2), connect the cable at J1 on the power interface board.

3. Reinstall the main control panel. See page 25.


J24 red/black J1 on precharge board, TB1 on DC bus filter board (AC input only)

TB1 on DC bus filter board (DC input only)

TB1 green/yellow PE on TB11

TB2 red #33, #34, and #35 on TB11

Connector Wire Color(s) Connects To:



Switch Mode Power Supply Board


Remove Components


2. Remove the main control panel as detailed on page 24.

3. Disconnect all cables ( J2, J4, J3, J1) from the switch mode power supply board.

4. Remove the switch mode power supply board mounting torx screw located at the lower right corner of the board.

5. Use your fingers or needle-nose pliers to squeeze the tabs of each of the three spacers and separate the switch mode power supply board from the mounting plate.

6. Remove the switch mode power supply board.

Install Components

1. Install the new switch mode power supply board. Torque the mounting screw to 1.7 Nm (15 lbin).

2. Connect J2, J4, J3, and J1 cables.

3. Reinstall the main control panel. See page 25.


Screw

Spacers



Precharge Board See Chapter 1 - Component Diagrams and Torque Specifications to locate the component detailed in these instructions.

Remove Components


2. Remove the safety cover over the precharge board.

3. For DC input only: Verify that customer wiring to TB2 is properly labeled and then disconnect wiring from TB2.

4. Using pliers if needed, remove the three wiring/harnesses ( J1, J2, J3).

Note: Some connectors may not be labeled. Label them if needed.

5. For AC input: Remove the precharge board mounting torx screw located at the upper left corner of the precharge board.

6. For AC input: Use your fingers or needle-nose pliers to squeeze the tabs of each of the three spacers and separate the precharge board from the mounting plate.

7. For DC input: Turn each of the six lock screws 1/4 turn counterclockwise to unlock.

8. Remove the precharge board.

Install Components

1. Install the new precharge board. For AC input: Torque the mounting screw to 1.7 Nm (15 lbin). For DC input: Turn each of the six lock screws 1/4 turn clockwise to

lock.

2. Connect the wiring.


Spacers

Screw

AC Input

Lock Screws (6)

DC Input



DC Bus Filter Board See Chapter 1 - Component Diagrams and Torque Specifications to locate the component detailed in these instructions.

Remove Components


2. Remove the safety cover over the DC bus filter board.

3. Disconnect red and black wires from TB1 and TB2 terminals.

4. Remove the four mounting bolts.

5. Remove the DC bus filter board.

Install Components

1. Install the new DC bus filter board. Torque the four mounting bolts to 1.7 Nm (15 lbin).

2. Connect the red and black wires to TB1 and TB2 terminals as shown at right.


TB2 TB1

TB2-3(red)

TB2-1(black)

TB1-3(red)

TB1-1(black)

Mounting Bolts (4)



Bus Capacitor See Chapter 1 - Component Diagrams and Torque Specifications to locate the component detailed in these instructions.

Remove Components


2. Remove the transitional busbar assembly as detailed on page 28.

3. Label and remove all wires and connectors from the bus capacitor busbar.

4. Remove nuts and washers (18 each) fastening the bus capacitor busbar to the capacitors.

5. Remove the bus capacitor busbar.

6. Remove the capacitors.

Bus Capacitor Busbar

Transitional Busbar Assembly Removed

Bus Capacitor BusbarNuts and Washers (18 each)



Install Components

1. Use a 3 mm angle hex wrench to replace the setscrews for each new capacitor. Torque to 0.7 Nm (6 lbin).

2. Place capacitors into correct position in drive (vent plug at top or 12 oclock).

3. Place bus capacitor busbar onto capacitors.

4. Install the 18 washers and nuts onto setscrews, but do not tighten yet.

5. Place the transitional busbar in position. Make sure that all setscrews, washers, and nuts fit. Adjust as needed.

6. Remove the transitional busbar, and tighten all washers and nuts for the bus capacitor busbar. Torque to 5.6 Nm (50 lbin).

7. Install the transitional busbar assembly as detailed on page 32.


ATTENTION: Install each capacitor so its vent plug is at the top or 12 oclock. Component and system damage may result if you position any bus capacitor incorrectly.

IMPORTANT Each capacitor needs a short and long setscrew. See the illustration below for where to install each setscrew.

Capacitors shown with Bus Capacitor

Busbar installed

Vent Plug (must be at top or 12 oclock)

Longer Setscrew for Transitional Busbar

Shorter Setscrew for Bus Capacitor Busbar



Capacitor Bank Fan See Chapter 1 - Component Diagrams and Torque Specifications to locate the component detailed in these instructions.

Remove Components



3. Label and disconnect all wires for the fan.

4. Remove the four mounting screws.

5. Remove the fan assembly.

Install Components

1. Install the new fan assembly. Torque the four mounting screws to 1.8 Nm (16 lbin).

2. Connect the wires.

3. Install the stacking panel as detailed on page 27.


Four Mounting Screw



Balancing Resistor See Chapter 1 - Component Diagrams and Torque Specifications to locate the component detailed in these instructions.

Remove Components



3. Label and disconnect all wires for the balancing resistor. Black: negative () busbar Yellow: bus capacitor busbar Blue: converter (+) busbar

4. Remove the two mounting screws.

5. Remove the balancing resistor.

Install Components

1. Use isopropyl alcohol to thoroughly clean the mounting surface of the transitional busbar and the mounting surface of the new balancing resistor.

2. Apply thermal grease to the mounting surface of the new balancing resistor. Torque the two mounting screws to 2.9 Nm (26 lbin).

3. Connect the wires for the balancing resistor. Torque the three screws to 2.9 Nm (26 lbin). Black: negative () busbar Yellow: bus capacitor busbar Blue: converter (+) busbar

4. Install the stacking panel as detailed on page 27.


Screw for Resistor black wire

Screw for Resistor blue wire

Screw for Resistor yellow wire

Balancing Resistor and Mounting Screws



Inverter Power Module (IGBT)

Kit includes:

Refer to the figures in Chapter 1 - Component Diagrams and Torque Specifications for these instructions.

Remove Components



3. Remove the AC output busbar at the current transducer:a. Remove and save the three bolts that secure the output busbar to the

AC output busbar and to the U, V or W busbar.

b. Remove and save the nut and threaded hex stud for the standoff. c. Slide the output busbar to the right as far as it goes.d. Remove and save the six screws that secure the AC output busbar to the

IGBT, and two nuts that secure the AC output busbar to its standoffs. Remove and save the AC output busbar.

4. Remove transitional busbar assembly as detailed on page 28.

Qty. Component

1 IGBT module with circuit board

1 gate interface board

1 Gate interconnect harness

3 Flexible capacitor busbar, positive (+)

3 Flexible capacitor busbar, negative (-)

1 Tie down capacitor mount

3 Snubber capacitor

IMPORTANT If any IGBT module is damaged, all IGBT modules and associated components should be replaced. Perform the following procedure for all IGBT modules.

Busbar Bolts (3)

Threaded Hex Stud and Nut



5. Remove the Gate Interface board. See page 53.

6. Carefully examine the transitional busbar and bus capacitors for damage.

When replacing any IGBT, Rockwell Automation recommends that you replace all bus capacitors. If needed, refer to Bus Capacitor on page 45 to replace damaged bus capacitors.

7. Remove the eight screws that secure the IGBT to the chassis.

8. Remove the IGBT by tipping the right edge out first.

Gate InterfaceBoard Assembly(not shown above)

Output Busbar


Snubber Capacitors

AC OutputBusbar

Current Transducer Assembly

IGBT

Flexible Capacitor Busbars

Transitional Busbar

Bus Capacitor, under Transitional Busbar

Example of IGBT Module Failure



Install Components

1. Install the IGBT module.a. Use isopropyl alcohol to thoroughly clean the mounting surface of the

heatsink and the mounting surface of the new IGBT module.b. Use a 3- or 4-inch paint roller or putty knife to apply a thin, even

coating of the supplied thermal grease to the mounting surface of the IGBT module.In the next step, take care to not disturb any of the thermal grease on the IGBT module.

c. Place the IGBT on the chassis with the serial number label at the top. Install with supplied screws using this torque sequence:

2. Install the three supplied positive flexible capacitor busbars in positions 2, 4, and 6 on the IGBT.

The positive flexible capacitor busbars have a shorter angle.

IGBT Torque Sequence

First Sequence: 0.7 Nm (6.0 lbin)Second Sequence: 2.3 Nm (20 lbin)

Final Sequence: 5.6 Nm (50 lbin)

Posi

tive

(+) F

lexi

ble

Capa

cito

r Bus

bars

1

2

3

4

5

6

Neg

ativ

e (-)

Fle

xibl

e Ca

paci

tor B

usba

rs

Shown with Transitional Busbar and all Flexible Capacitor Busbars installed for illustration purposes only.



3. Install the transitional busbar assembly. See page 32.

Only torque nuts and screws after all components are in place.

4. Install the three supplied negative flexible capacitor busbars in positions 1, 3, and 5 on the IGBT.

The negative flexible capacitor busbars have a higher angle.

5. Install the tie down capacitor mount:a. Insert the short ends of the six threaded studs with nuts through the

flexible capacitor busbars and into the left side of the IGBT. Torque to 5.6 Nm (50 lbin).

b. Install the tie down capacitor mount with the two screws previously removed from the top and bottom of the capacitor mount. Torque to 2.9 Nm (26 lbin).

6. Install the AC output busbar, output busbar, and current transducer:a. Secure the AC output busbar to the two standoffs using the two nuts

previously removed. Torque nuts to 5.6 Nm (50 lbin).b. Secure the AC output busbar to the IGBT by inserting six screws into

the IGBT. Torque screws to 5.6 Nm (50 lbin).c. If removed, insert the output busbar through the current transducer

assembly with the large end to the right.d. Secure the current transducer assembly (transducer and brackets) using

the two screws that were removed with the assembly. Torque to 2.9 Nm (26 lbin).

e. Secure the left end of the output busbar to the AC output busbar with one screw. Torque to 9.0 Nm (80 lbin).

f. Secure the other end of the output busbar to the U, V, or W busbar with the setscrew and nut. Torque the nut to 5.6 Nm (50 lbin).

g. Install the two screws that connect the output busbar to the U, V, or W busbar. Torque to 9.0 Nm (80 lbin).

7. Install the gate interface board:a. Install the gate interface board using the four nuts removed previously.

Torque screws to 2.9 Nm (26 lbin).b. Install the supplied Gate Interconnect Harness.c. Connect wiring between the IGBT and gate interface board as shown

in Gate Interface Board on page 53.d. Connect wires to the current transducer.

8. Install the three snubber capacitors in the reverse order of the removal instructions detailed on page 29. Torque nuts to 5.6 Nm (50 lbin).


WARNING: Correct torque is critical to ensure correct operation of the drive. Improper torquing could cause premature failure when attempting to operate the drive.



Gate Interface Board See Chapter 1 - Component Diagrams and Torque Specifications to locate the component detailed in these instructions.

Remove Components


2. Remove the safety cover over the gate interface board.

3. Label and disconnect all wires ( J1 . . . J8).

4. Remove the four mounting nuts and remove the board.

Install Components

1. Install the new board. Torque the four mounting nuts to 1.8 Nm (16 lbin).

2. Connect J1 . . . J8 wires as shown above.

NOTE: J4 from the corresponding IGBT connects to J6 on the gate interface board.


Gate Interface BoardMounting Nuts (4)

J1

J2

J3

J5

J4J6

J8

J7



Current Transducer See Chapter 1 - Component Diagrams and Torque Specifications to locate the component detailed in these instructions.

Remove Components


2. Label and disconnect the wire from the transducer.

3. Remove the two 17 mm bolts and one 11 mm nut that connect the U, V, or W busbar to the output busbar.

4. Remove the bolt on the left end of the output busbar.

5. Use a hex wrench to remove the setscrew.

6. Remove the two screws that secure the transducer assembly to the backplane (transducer and brackets).

Current Transducer

Transducer Brackets

Output Busbar

Setscrew



7. Remove assembly by lifting the assembly up and turning it slightly counterclockwise while rotating the top of the output busbar toward you and around the U, V, or W busbar.

8. Move the busbar and transducer to an ESD-safe flat surface for working with it.

9. Separate the transducer from the brackets.

Install Components

1. Mount brackets to the transducer. Torque screws to 1.6 Nm (14 lbin).

2. Slide output busbar through the current transducer assembly with the angled end to the left.

3. Replace the current transducer assembly in mounting position by reversing the process used in Step 7. of the removal process.

4. Secure the transducer assembly to the drive chassis with two screws. Torque to 2.9 Nm (26 lbin).

5. Replace the output busbar setscrew and nut. Torque the nut to 5.6 Nm (50 lbin).

6. Install the three output busbar bolts. Torque to 9.0 Nm (80 lbin).





Converter Power Module - (SCR) AC Input Only


Remove Components



3. Remove all three converter snubber boards and set them aside.a. Label and disconnect wires from the converter snubber board.b. Remove the two screws that secure the board. c. Remove the board and set aside.

4. Note the orientation of the converter busbars and remove the eight bolts that secure the busbars to the converter SCR modules and to the DC+ and DC- busbars. Set the converter busbars aside.

IMPORTANT If any converter SCR module fails, all three SCR modules should be replaced (kit includes three SCR modules).

R S T

Converter Snubber Boards

Converter SCR Modules

DC-D

Snubber Board Standoff (Does not need to be removed.)

Converter Busbar, Lower

Converter Snubber BoardsSerial Number Label R S T

Converter SCR Modules

Converter Busbar, Upper



5. Disconnect the three AC busbars (R, S, T) at the top only.

You do not need to remove the wires from the AC busbars.

6. Label and note the position of the converter SCR module leads. Remove the leads.

Typically, the leads are marked as R, S, or T, and each is notched with the notch to the front of the converter SCR module.

7. Remove the four Phillips screws that hold each converter SCR to the heatsink and remove the converter SCR modules.

Install Components

1. Use isopropyl alcohol to thoroughly clean the mounting surface of the heatsink and the mounting surface of each new converter SCR module.

2. Use a 3- or 4-inch paint roller or putty knife to apply a thin, even coating of the supplied thermal grease to the mounting surface of each new converter SCR module.

3. Install each new converter SCR module with supplied screws and tighten using this torque sequence:

4. Replace the SCR module leads.

Each set of leads is marked R, S, or T. The notch and red wire on each lead are positioned to the front.

5. Install the converter busbars per diagram in step 2 and torque to 9.0 Nm (80 lbin).

6. Install the snubber boards, oriented with the serial number at the top, and torque to 2.9 Nm (26 lbin).

7. Replace the wires from the converter snubber resistors to the snubber boards.

The black wire goes to J1. The blue wire goes to J2.

8. Reinstall AC busbars (R, S, T). Torque to 9.0 Nm (80 lbin).

IMPORTANT In the next step, take care to not disturb any of the thermal grease on the converter SCR module.

SCR Torque

First Sequence:0.7 N-m (6.0 lb.-in.)

SCR Torque

Final Sequence:5.6 N-m (50 lb.-in.)



9. Reinstall the DC+ and DC- busbars and torque to 9.0 Nm (80 lbin).

10. Install stacking panel as detailed on page 27.


Converter Snubber Resistors - AC Input Only


Remove Components

Kit includes snubber board and resistor.



3. Verify the snubber resistor(s) with a volt ohm meter. The reading should be 8 ohms 10%. If the reading is not within tolerance, perform the remainder of this

procedure. If the reading is within tolerance, do not perform the remainder of this

procedure.

4. For the R snubber resistor only: Remove the transitional busbar assembly as detailed on page 28.

5. Label and disconnect the wires from snubber resistors that will be replaced.

6. Remove the resistor.

Snubber Resistor for R SCR Snubber Resistor for S SCR

Snubber Resistor for T SCR



Install Components

1. Use isopropyl alcohol to thoroughly clean the mounting surface of the heatsink and the mounting surface of the new snubber resistor.

2. Use a 3-inch paint roller or putty knife to apply a thin even coating of the supplied thermal grease to the mounting surface of the new snubber resistor and install. Torque screws to 2.9 Nm (26 lbin).


4. For the R snubber resistor only: Install the transitional busbar assembly as detailed on page 32.



Converter Snubber Board - AC Input Only


Remove Components



3. Label and disconnect wires from the converter snubber board to be replaced.

4. Remove the two screws that secure the board.

5. Remove the board.

Snubber Board for R SCR Snubber Board for S SCR

Snubber Board for T SCR



Install Components

1. Install the new snubber board. Torque screws to 2.9 Nm (26 lbin).


Black wire goes to J1. Blue wire goes to J2.



Fan Transformer See Chapter 1 - Component Diagrams and Torque Specifications to locate the component detailed in these instructions.

Remove Components


2. Label and unplug or disconnect the five wires for the fan transformer.

3. Unscrew the four fan transformer mounting bracket screws.

Install Components

1. Install new fan transformer. Torque four screws to 5.6 Nm (50 lbin).

2. Connect the wires for the fan transformer.


Fan Transformer

Label and unplug these two red wires

Label and disconnect these three wires

Mounting bracket screws (4)



Heatsink Fan - Removal from Back of Drive

The heatsink fan is located on the back of the drive.

(For equipment clearance considerations, the fan can also be removed from the front of the drive. See Heatsink Fan - Removal from Front of Drive on page 63.)


Remove Components


2. Verify that there is at least a 91 cm (3 ft) clearance in back of the drive for access to the heatsink fan.

3. From the front of the drive, disconnect the cables for both the fan and the fan capacitor.

Access the cables by gently pulling the wiring from behind the busbar mounting panel.

4. On the back of the drive, remove the eleven screws for the fan cover; see the figure on the next page for the screw locations.

Do not remove the screws for the screen.

5. Use the handle to separate the fan assembly from the drive enclosure.

Some force may be needed to separate the fan from the enclosure as the gasket may be tight or sticky.

Disconnect here

Press tabs in for removal

Front of driveConnectors



6. Remove the fan.

Install Components

1. Install the new gasket (if the old gasket was damaged).

2. Place the fan assembly into the chassis but not installed in final position. Leave space for accessing fan cables from the front of the drive.

Take care to not pinch wires.

3. From the front of the drive, connect the fan cables.

4. Place fan assembly in final position in the chassis.

5. On the back of the drive, install the eleven screws for the heatsink fan cover. Torque to 2.9 Nm (26 lbin).

TIP The connectors, one set shown below, are designed so they go together only one way. The two end sections are flat on one side and each section has a ridge at the matching edge.

Fan Cover Screw Locations on Back of Drive

Four on top and bottom for a total of eight

Three on right sideNOTE: No screws on left side

Fan Assembly (Front View), Removed from Drive

Ridges

Flat Sections

Connectors shown slightly separated



Heatsink Fan - Removal from Front of Drive

The heatsink fan is located on the back of the drive. These instructions explain how to remove the fan from the front of the drive.


Remove Components


2. Disconnect all appropriate wiring to AC and DC busbars so you can remove entire set of busbars with the busbar mounting plate in a later step.


4. Disconnect the DC+ and DC- busbars that connect to the converter busbars at the top of each bar.

Heatsink Fan behind mounting plate



Do not disconnect the U, V, or W busbars at the bottom.

5. Disconnect all busbars where they connect to the converter SCR modules with 16 mm bolts. Disconnect wiring.


17 mm bolt on DC Busbar

17 mm bolt on DC+ Busbar

Do not disconnect Busbars at the bottom.

AC Drive Shown

16 mm bolts

Do not disconnect Busbars at the bottom.

AC Drive Shown



6. Disconnect the U, V, and W busbars at the top of each bar where they connect to the output busbars for the current transducers with two 17 mm bolts and one 11 mm nut.

Do not remove the busbars from the setscrew on the output busbars at this time.


7. Remove the four 10 mm nuts for the busbars mounting plate.

Setscrew after 11 mm nut is removed

Output Busbar

17 mm bolts

11 mm nut

Current Transducer

Busbar Mounting Plate

10 mm nuts (4)



8. Remove the entire busbar and mounting plate assembly. Set aside.

9. Unplug the fan cables.

10. For AC drives, remove the MOV surge suppressor as detailed on page 71.

11. Remove the left busbar mounting plate bracket.

12. Remove the 12 exterior screws on the fan mounting plate.

13. Carefully remove the mounting plate and fan through the front of the drive chassis; you may need to pry the mounting plate away from the gasket.

The fan housing remains mounted on the chassis.

Fan Mounting Plate Screws (12)

Busbar Mounting Plate Bracket, Removed



Install Components

1. Remove the new fan housing from the new fan and mounting plate.

Discard the new fan housing.

2. Install the new gasket (if the old gasket was damaged) and mounting plate to the chassis. Torque the mounting screws to 2.9 Nm (26 lbin).

3. Install the left busbar mounting plate bracket. Torque the mounting screws to 5.6 Nm (50 lbin).

4. For AC drives, install the MOV surge suppressor as detailed on page 71.

5. Connect the fan cables.

6. Install the busbar and mounting plate assembly:a. Torque the four 10 mm nuts for the busbar mounting plate to 5.6 Nm

(50 lbin).b. Torque the 11 mm mounting nut on the setscrew for each U, V, and W

busbar at the current transducer output busbar to 5.6 Nm (50 lbin).c. Torque the two 17 mm mounting bolts for each U, V, and W busbar at

the current transducer output busbar to 9 Nm (80 lbin).d. Torque the three 16 mm mounting bolts for the busbar connection to

the converter SCR modules to 9 Nm (80 lbin).e. Torque the six wiring screws for the busbar connection to the converter

SCR modules to 2.9 Nm (26 lbin).f. Torque the 17 mm mounting bolts for the DC+ and the DC- busbars

(one each) that connect to the converter busbars to 23.5 Nm (208 lbin).




Thermal Sensors The thermal sensor system consists of: A sensor secured to the upper

mounting bracket for the main control panel.

A sensor secured to the heatsink above the SCR modules.

A connector to J8 on each of the three gate interface boards.


HeatsinkThermalSensor

Main ControlPanel ThermalSensor

J6J8

-UJ8

-VJ8

-W

2 w

ires

4 w

ires

2 w

ires

BA

PowerInterfaceBoard

Thermal Sensor wiring for both drives



Remove Components


2. Cut the wire ties for the wiring harness along the gate interface boards.

3. Note wire routing and location of sensors.

4. For the main control panel thermal sensor, remove the screw and nut on the main control panel and disconnect the other end from the wiring harness.

5. For the Heatsink thermal sensor, remove the screw on the Heatsink above the SCR modules and unplug the other end from the wiring harness.

6. Label the wires and unplug the J8 connectors on each of the three gate interface boards, and unplug the other end of this wiring harness at the J6 connector on the power interface board.

Install Components

1. Use isopropyl alcohol to thoroughly clean the mounting surface of the control panel and heatsink, and the mounting surface of the thermal sensors.

2. Apply a thin layer of supplied thermal grease to the

Date post:	17-May-2018
Category:	Documents
Upload:	doankhuong
View:	213 times
Download:	0 times

PowerFlex 700 Drive - Frame 8 Components … Automation Publication 20B-IN024C-EN-P - June 2012 9...

Documents